Dual wall fabric with circular connection points

ABSTRACT

A dual wall fabric is provided, having integrally woven connection points, of circular configuration, the fabric being adapted to be filled with concrete or like filler material pumped between the layers. A means is provided for connecting the two layers together in such a fashion, that when concrete is pumped between the layers, a void may be provided, extending through the concrete mat formed upon setting-up of the concrete.

References Cited UNITED STATES PATENTS 5/1955 Foster 139/384X 139/410139/384X l39/384X 139/410X guration, the'fabric being adapted to befilled with concrete or like filler material a void may be proextendingthrough the concrete mat formed upon 2,632 480 3/1953 Maclntyre..

3,008 214 11/1961 Foster et a1.....

3,294 605 12/1966 Fischer.........................

3,328 218 6/1967 Noyes.............

Primary ExaminerJames Kee Chi Attorney- Paul and Paul ABSTRACT: A dualwall fabric is provided, having integrally woven connection points, ofcircular confi pumped between the layers. A means is provided forconnecting the two layers together in such a fashion, that when concreteis pumped between the layers,

vided setting-up of the concrete.

Durham; Robert G. Currier, Roxboro, N.C. [211 App]. No. 764,203

Oct. 1, 1968 [45] Patented Feb. 23, 1971 Collins and Aikman CorporationNew York, N.Y.

CONNECTION POINTS 8 Claims, 5 Drawing Figs.

[52] U.S. 139/384, 139/410 D03d 3/00, D03d 1 1/00 61/37, 38, 35;139/408-414, 384, 387389 United States Patent [72] Inventors John T.Hayes [22] Filed [73] Assignee [54] DUAL WALL F ABRIC WITH CIRCULAR [50]Fieldo1'Search............................................

a? me 1 3. a e amon e r t iuthmnmml nu l PATENTEnfiazalsn 3,565,125

sum 1 OF 2 J h INTYEIEIITORS. i I o n ayes 1 BY Robert G. Currier MPMATTORNEYS.

DUAL WALL FABRIC WITH CIRCULAR CONNECTION POINTS BACKGROUND OF THEINVENTION According to recent developments in the containment art, thetechnology has advanced to the making of containment fabrics of dualwall construction, for various purposes, such as for p roviding materialfor mattresses, inflatable or noninflatable, for providing material ofmattresslike configuration which may be pumped full of concrete or thelike, and generally for providing material adapted for receiving afiller therein, in any application wherein dual wall fabric may beuseful.

A principal use for dual wall fabric has been in the area of cementcontainment, as for example in the formation of erosion dams, in theformation of concretecoverings for river banks, in forming concreteliners for water canals, and like applications. The dual wall fabric hasbeen found to be extremely useful in such applications, in that it hassaved the time consuming operations of sewing a plurality of sheetstogether.

In the course of the development of dual wall cement containmentfabrics, it has been found that it has been necessary to make connectionpoints between the opposed fabric layers. The reason for this is that,as concrete, cement or the like is pumped between a mattress or'likeconfiguration of dual wall fabric, the concrete filler material tends toassume a round configuration, much the same as the configuration assumedby a balloon, upon" blowing the same full of air. Thus, in order tomaintain the desired flat or mattresslike configuration of a dual wallcement containment fabric, connection points have been'placed in thefabric. I i

It has further been found that it has been most economical to weave suchconnection points integral with the weaving of the face cloth and backcloth comprisingthe dual wall fabric,

and accordingly, there has been developed the technique of weaving theconnection points integrally between the face cloth and back cloth bymeans of threads which are woven in the warp direction to engage weftthreads of the face cloth and back cloth, and to hold the same togetheragainst each other.

As a further modification of this state of development, it has beenfound that, upon filling afmattress" of dual wall fabric thus formedwith concrete, a high degree of stress would be imparted to variousportions of the connection points between the opposed fabric layers,inasmuch as such connection points would generally be of rectangularconfiguration, whereas the concrete being pumped into the fabric tendedto assume an oval, circular or other arcuate shape when contained withinthe fabric. Such rectangular corners on the connection points would thustend to rip under the pressure of the concrete being applied between thefabric layers, and consequently the pressure of concrete being appliedbetween dual wall fabric had to be carefully controlled, and kept belowa predetermined level, in order to avoid ripping the connection pointsand allowing the concrete to escape. By limiting the pressure which theconcrete could attain within the dual wall fabric, the necessary pumpingdistance of concrete being inserted into the fabric was also limited, inthat, as the concrete being pumped traveled to a point between theopposed fabric layers which was remote from its point of entry, thepressure on those connection points most adjacent the point of entrywould increase substantially above the concrete pressure at pointsremote from its point of entry into the fabric. Consequently, severelimitations have been placed upon concrete pumping between opposedlayers of dual wall fabric.

Additional problems have been present in dual wall concrete containmentfabrics, such as the provision of some means for water seepage orpassage, when the same is desirable, between opposite sides of ahardened concrete construe tion, as well as the provision of some meansfor easily and economically forming a clearance hole, duct, or like voidbetween opposite sides of a hardened concrete-filled dual wallcontainment fabric, and the provision of the same with substantial ease,during the formation of such a construction.

SUMMARY OF THE INVENTION A dual wall containment fabric havingintegrally woven connection points is provided, wherein the connectionpoints are designed such that each portion of the periphery of eachconnection point is capable of withstanding the same pressure, in thatno zones of stress concentration are provided, in that the connectionpoints are generally of circular configuration. Another principalfeature of novelty is that, that portion of fabric which comprises thecircular connection points is woven by a Jacquard head motion, whereasthe remainder of such fabric is woven by a Dobby head motion, anefficient combination and utilization of the two weaving processes, toyield a single fabric having the desired results.

Accordingly, it is a primary object of this invention to provide a noveldual wall containment fabric capable of receiving a filler material,whereby stress concentration points at fabric layer connections are avoied.

It is a further object of this invention to accomplish the above object,wherein circular connection points are provided between opposed fabriclayers.

It is yet another object of this invention to accomplish the aboveobjects, using the novel method of weaving the fabrics together by acombination of Jacquard head weaving and Dobby weaving.

It is a further object of this invention to accomplish all of theobjects above, wherein the dual wall fabric connection points are eachof two different weaves, one weave surrounding the other, with theinnennost weave being of more loose or open construction, to permit thepassage of moisture, water or the like therethrough.

It is a further object of this invention to provide a novel device forfacilitating the formation of dual wall containment fabrics, wherein thefabrics are to be filled with the filler material, and wherein a meansis provided for allowing a void or passageway through the fillermaterial, during the formation of a containment structure.

Other objects and advantages of the present invention will be readilyapparent to one of ordinary skill in the art from the reading of thefollowing brief descriptions of the drawing figures, detaileddescriptions of the preferred embodiments, and the appended claims.

IN THE DRAWINGS FIG. 1 is a top plan view of a dual wall containmentfabric, looking at a face cloth, and wherein there is illustrated inphantom a portion of another containment fabric adapted for sewingalongside the rightmost edge of the containment fabric shown in fulllines, for enlarging the width of such a fabric.

FIG. 2 is an enlarged detailed view of a connection point of the fabricillustrated in FIG. 1, in approximately full scale.

FIG. 3 is an enlarged transverse sectional view, taken through thecontainment fabric if FIG. 1, generally along the line III-III of FIG.1, and wherein the fabric is illustrated with a concrete filler materialcontained therein.

FIG. 4 is an enlarged transverse sectional view, taken through the portor void illustrated in FIG. 1, generally along the line IV-IV of FIG. 1,and wherein the manner of attachment of the end structures to the sleevewhich forms the void in the filled containment fabric is clearlyillustrated.

FIG. 5 is an enlarged schematic view of a portion of the circular tiepoint weave illustrated in FIG. 2, and its connection to the opposedfabric layers, taken generally along the line V-V of FIG. 2.

Referring now to the drawings in detail, reference is first made to FIG.1, wherein there is illustrated a dual wall fabric of this invention,generally designated by the numeral 10, and with reference. also to FIG.3, comprising opposed fabric layers 11 and 12 which comprise the facecloth and the back cloth, respectively.

In the embodiment illustrated in FIG. 1, the leftmost side of the facecloth 11 is illustrated as having a selvage 14, which integrallyconnects the upper end lower or face cloth and back cloth layers 11 and12.

The selvage 14 is shown only on the leftmost side of the fabric 10,extending in the warp direction, and is absent from the rightmost sidethereof, in order to facilitate sewing of the dual wall fabric to asimilar but mirror-imaged section of dual wall fabric 15, as for examplethat illustrated in phantom lines in FIG. 1, such that the connectionbetween tie points thereof (to be described in greater detailhereinafter) will be approximately the same between connection points ofdifferent dual wall fabrics as between connection points of the samedual wall fabric. Thus, the dual wall fabrics 10 and 15 are connectedtogether along a stitching line 16, which does not connect opposedfabric face cloths to back cloths and the converse.

Traversing the dual wall fabric 10 in the weft direction, it is seenthat, starting with the selvage strip 14, a plurality of altemate stripsare provided, each woven in the warp direction. Adjacent to the strip14, is a strip 17, of any suitable weave, for providing a fabric layer.The strip 17 is woven by a Dobby head motion, by the conventionaltechnique. Simultaneously with the weaving of the strip 17, the strip18, disposed adjacent thereto is woven by a Jacquard head motion, toalso comprise a portion of a single fabric layer, spaced from anadjacent portion of the back cloth 12 disposed therebeneath (not shown).Similarly, alternate strips 20, 21 and 22, 23 are provided woven in asimilar manner to those 17 and 18, respectively. The end strip 24,between the strip 23 and the free edge 16 may be of the thickness ofeither of the strips 17, 20 or 22, but is illustrated as comprisingapproximately half that thickness for the purpose mentioned above, offacilitating the connection of the fabric 10 to the fabric 15.

Each of the strips 18, 21 and 23 is illustrated as having a plurality ofconnection points or zones 25, aligned within the strips 18, 21 and 23,and spaced equidistantly therefrom in a warp direction. Also, theconnection points 25 are spaced so as to be in alignment in the weftdirection, although such is not necessary, in that a staggered effectmay be obtained, if desired.

With particular reference to FIG. 2, the circular connection point 25 isseen to have a periphery 26 of generally circular configuration. Such aconfiguration is one which allows minimum chances of stressconcentration, although it is to be understood that an oval or otherarcuate peripheral configuration would be more advantageous in thisregard than a rectangular configuration, but less advantageous than acircular configuration. The connection points 25 also each comprise twobasic weave patterns, to complete the tie point pattern. An outermostportion 27 is provided, comprising a compact rib weave, and surrounds aninnermost portion 28 which is of square configuration and comprises anopen mock leno weave.

This particular design with a circular tie point combines maximumstrength of the rib weave at the circumference of the circle with anopen center portion 28 which allows filtering of water under hydrostaticpressure between the back cloth l2 and the face cloth 11.

With particular reference to FIG. 5, there is illustrated a portion ofthe strip 23 as viewed, looking in the weft direction, across a circulartie point 25. Warp strands 30 and 31 are illustrated being woven in arib weave about the weft strands 32, to comprise the back cloth, withthe strands 30 and 31 separating as they enter the periphery 26 of thecircular connection point 25, the strands 30 and 31 then being wovenaround opposite sides of weft strands 33, through the zone 25, in themanner illustrated, to reenter the back cloth 12 as illustrated beneathof connection point 25. The warp strands 36 and 37 which comprisecomponents of the face cloth 11 are similarly woven about the weftstrands 38, the weft strands 33, passing through the connection zone 25and the weft strands 38 at the lower end of the schematic illustrationof FIG. 5. It will be noted that the view of FIG. 5 is taken at thepoint that it does not include a schematic cross section of therectangular portion 28 of the connection point 25, for clarity ofillustration.

With reference to FIG. 3, there is illustrated the manner in whichconcrete 40 tends to assume an oval configuration when pumped betweenopposed fabric layers 11 and 12 which are connected by connection points25. It will be understood that any type of filler material, such asplastic foam or the like, in addition to concrete or cement may beutilized, all to be encompassed within the term concrete," as usedherein. Furthermore, other similar materials which lend themselves toconforming to a desired configuration in situ, such as water extendedpolyester may also be used.

With particular reference to FIG. 4, there is illustrated the manner inwhich a void may be formed in a solid concrete mat. A sleeve 41, havingopen ends 42 and 43 may be disposed between the opposed fabric layers 11and 12, with the open ends 42 and 43 in abutment with inner surfaces ofthe layers 12 and 11 respectably. A pair of opposed cups 44 and 45 arethen provided, disposed over the ends of the sleeve 41, to engage fabricportions 46 and 47 and to clamp the same between the cups 44 and 45 andthe inner bore of the sleeve 41, at the ends 42 and 43 thereof. Flanges48 and 50, extending outwardly from the cups 44 and 45 limit the entryof the cups 44 and 45 into the sleeve 41. Y

The cups 44 and 45 are provided with inner bores 51 and 52 respectively,such that the associated encircled fabric layer portions 53 and 54 mayreadily be removed at this time, if the same is desired. In thealternative, the concrete 40 may be pumped into the space between theopposed layers 11 and 12, after the sleeve 41 is in place and the endcaps or cups 44 and 45 secured in position, and after the concrete 40sets up or hardens, the cups 44 and 45 may be removed and those portions46 and 47 of the fabric layers 12 and 11 respectively may then be cutaway. In either instance, whether the cups 44 and 45 remain within thesleeve 41, or are withdrawn, a void or port 55 is provided, through thecontainment construction of FIG. 4, through which water, power, or likeutility lines may be installed, should the construction comprise a partof an assembly requiring utilities of this type. In the event that thefabric construction 10 is utilized to form a moveable bunker, it may bedesirable to attach a cable or the like to the construction through thevoid 55, for dragging the same from one position to another.

It will be apparent from the foregoing, that various modifications maybe made in the details of construction, as well as in the use andoperation of the various features of this invention, all within thespirit and scope of the invention, as claimed. It will further beapparent that the term connection point comprises a connection zone. Itwill further be apparent that any desired strand material may be used tocomprise the warp and weft yarns, such as nylon, polypropylene, or splitfilm yarns. Additional yarns may also comprise polyvinylchloride andpolyolefin yarns of various types.

We claim:

1. A dual wall containment fabric for use in containing a hardenablefiller therein during setup having integrally woven thread strandsconnecting opposed fabric layers of double cloth weave wherein aplurality of said connecting strands cooperate to define a connectionzone of generally circular configuration, with the opposed fabric layersin said zone being disposed against each other.

2. The fabric of claim 1, wherein the circular connection zone forms arepetitive pattern in both warp and weft directions of the double clothfabric.

3. The fabric of claim 2, wherein each said connection zone comprises anoutermost portion of tight weave construction which surrounds aninnermost portion of loose weave construction relative to said outermostportion.

4. The fabric of claim 3, wherein said innermost portion is ofrectangular configuration.

5. The fabric of claim 3, wherein said outermost portion comprises a ribweave.

6. The fabric of claim 3, wherein said innermost portion comprises anopen mock leno weave.

7. A dual wall containment fabric having integrally woven connectionpoints between opposed layers of the fabric, for

sertion of filler material between said layers. wherein said peripheralconfiguration comprises a substantially circular configuration.

8. The fabric of claim 7, wherein each said connection point is ofgenerally circular configuration.

1. A dual wall containment fabric for use in containing a hardenablefiller therein during setup having integrally woven thread strandsconnecting opposed fabric layers of double cloth weave wherein aplurality of said connecting strands cooperate to define a connectionzone of generally circular configuration, with the opposed fabric layersin said zone being disposed against each other.
 2. The fabric of claim1, wherein the circular connection zone forms a repetitive pattern inboth warp and weft directions of the double cloth fabric.
 3. The fabricof claim 2, wherein each said connection zone comprises an outermostportion of tight weave construction which surrounds an innermost portionof loose weave construction relative to said outermost portion.
 4. Thefabric of claim 3, wherein said innermost portion is of rectangularconfiguration.
 5. The fabric of claim 3, wherein said outermost portioncomprises a rib weave.
 6. The fabric of claim 3, wherein said innermostportion comprises an open mock leno weave.
 7. A dual wall containmentfabric having integrally woven connection points between opposed layersof the fabric, for use in receiving a solid-forming filler materialapplied under pressure between said layers, said connection pointsproviding a means to restrain separation of the fabric layers as thefiller material is being applied therebetween, said connection pointseach comprising a predetermined area having a peripheral configurationwhich defines means for preventing stress concentration at portions ofconnection point periphery during insertion of filler material betweensaid layers, wherein said peripheral configuration comprises asubstantially circular configuration.
 8. The fabric of claim 7, whereineach said connection point is of generally circular configuration.